JP2006130715A - Trim material having undulated surface and its molding method - Google Patents

Trim material having undulated surface and its molding method Download PDF

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JP2006130715A
JP2006130715A JP2004320261A JP2004320261A JP2006130715A JP 2006130715 A JP2006130715 A JP 2006130715A JP 2004320261 A JP2004320261 A JP 2004320261A JP 2004320261 A JP2004320261 A JP 2004320261A JP 2006130715 A JP2006130715 A JP 2006130715A
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fabric
skin material
thermoplastic resin
mold
cushion layer
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Japanese (ja)
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Yasuyuki Shimizu
康之 清水
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Toyota Boshoku Corp
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Toyota Boshoku Corp
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a trim material having an undulated surface constituted by molding an arbitrary undulated shape to the surface of a skin material at the same time during a process for integrally molding the skin material and a thermoplastic resin, and its molding method. <P>SOLUTION: After the skin material 1, which is produced by laminating a fabric 1a, a cushion layer 1b and a back base fabric 1c from a surface side, is set to the inside of a mold, a molten thermoplastic resin 3 is injected to mold the trim material wherein the skin material 1 and the thermoplastic resin 3 are integrated, a fabric, which has a difference in its heat shrinkage factor in its longitudinal and lateral directions and is prepared by welding the fabric 1a and the back base fabric 1c through the cushion layer 1b in a dot form at least at two points in the direction large in the heat shrinkage factor, is used as the fabric 1a. By this constitution, the fabric 1a is shrunk between the dot like welded parts 2 and 2 by the heat received from the molten resin at the time of injection of the molten thermoplastic resin in the mold so as to be biased in the direction large in the shrinkage factor to form recessed stripe patterns 4 to the surface of the skin material 1. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

本発明は、表皮材と熱可塑性樹脂とを一体成形する工程の中で、表皮材の表面に任意の起伏形状を同時に成形してなる表面に起伏を有する内装材とその成形方法に関するものである。   The present invention relates to an interior material having undulations on a surface formed by simultaneously molding an arbitrary undulation shape on the surface of a skin material in a process of integrally forming a skin material and a thermoplastic resin, and a molding method thereof. .

例えば、ドアトリム等の自動車用内装材として、従来から表皮材と熱可塑性樹脂とを一体成形したものが広く使用されている。このような内装材は、表皮材を金型内にセットした後、溶融した熱可塑性樹脂を注入することにより成形されているのが普通である。一方、最近ではユーザー等の好みも多様化しており、ファブリックからなる表皮材にも皮革のようなギャザー模様や凹凸模様を設けて高級感をかもし出すものが要求されつつある。   For example, as an automotive interior material such as a door trim, a material obtained by integrally molding a skin material and a thermoplastic resin has been widely used. In general, such an interior material is formed by injecting a molten thermoplastic resin after setting the skin material in a mold. On the other hand, the preferences of users and the like have recently diversified, and there is a demand for a leather-made skin material that is provided with a gathered pattern or uneven pattern like leather to bring out a high-class feeling.

そこで、例えば特許文献1に示されるように、ポリウレタン弾性体からなる表皮層に伸縮性をもたせた皮革様シート状物も提案され、各種のニーズに対応する試みがなされている。しかしながら、ファブリックからなる表皮材にも皮革のようなギャザー模様や凹凸模様を一体的に設ける技術は完成されておらず、この場合は後加工によるしか方法がなかった。この結果、成形工程が複雑になるとともに生産性にも劣り、またコスト的にも高くなるという問題点があった。
特開平6−293117号公報
Therefore, for example, as disclosed in Patent Document 1, a leather-like sheet-like material having a stretchable skin layer made of a polyurethane elastic body has been proposed, and attempts to meet various needs have been made. However, a technique for integrally providing a gather pattern or uneven pattern such as leather on the fabric skin material has not been completed, and in this case, there was only a method by post-processing. As a result, there are problems that the molding process becomes complicated, the productivity is inferior, and the cost increases.
JP-A-6-293117

本発明は上記のような従来の問題点を解決して、ファブリックからなる表皮材と熱可塑性樹脂とを一体成形する工程の中で、表皮材の表面に起伏形状を一体的に成形することができ、また任意のデザインの起伏形状を形成することができ、更には生産性に優れて大幅なコストダウンも図ることができる表面に起伏を有する内装材とその成形方法を提供することを目的として完成されたものである。   The present invention solves the conventional problems as described above, and in the process of integrally forming the skin material made of fabric and the thermoplastic resin, the undulating shape can be integrally formed on the surface of the skin material. An object is to provide an interior material having undulations on the surface and a forming method thereof, which can form undulation shapes of any design, and can further achieve a significant cost reduction with excellent productivity. It has been completed.

上記課題を解決するためになされた本発明は、表面側からファブリック、クッション層、裏基布を積層した表皮材を金型内にセット後、溶融した熱可塑性樹脂を注入して表皮材と熱可塑性樹脂とを一体成形した内装材であって、前記ファブリックが縦横の熱収縮率に差を有しているとともに、ファブリックと裏基布とがクッション層を介して、熱収縮率の大きい方向に2点以上、ドット状に溶着されたものであり、表皮材表面には金型内に溶融した熱可塑性樹脂を注入した際の溶融樹脂からの受熱により、前記ドット状の溶着部間においてファブリックの熱収縮率の大きい方向に偏ってファブリックが縮んで生じた凹み筋模様が形成されていることを特徴とする表面に起伏を有する内装材を第1の発明とするものである。
また、表面側からファブリック、クッション層、裏基布を積層した表皮材を金型内にセットした後、溶融した熱可塑性樹脂を注入して表皮材と熱可塑性樹脂を一体成形した内装材の成形方法であって、前記ファブリックとして縦横の熱収縮率に差を有しているとともに、ファブリックと裏基布とがクッション層を介して、熱収縮率の大きい方向に2点以上、ドット状に溶着されたものを用い、金型内に溶融した熱可塑性樹脂を注入した際に溶融樹脂からの受熱により、前記ドット状の溶着部間においてファブリックの熱収縮率の大きい方向に偏ってファブリックを縮ませて表皮材表面に凹み筋模様を形成することを特徴とする内装材の成形方法を第2の発明とするものである。
In order to solve the above problems, the present invention provides a skin material laminated with a fabric, a cushion layer, and a back base fabric from the front side in a mold, and then injects a molten thermoplastic resin to heat the skin material and heat. An interior material integrally molded with a plastic resin, wherein the fabric has a difference in the vertical and horizontal heat shrinkage ratios, and the fabric and the back base fabric have a large heat shrinkage ratio through the cushion layer. Two or more dots are welded in the form of dots, and the surface of the skin material receives heat from the molten resin when the molten thermoplastic resin is injected into the mold, so that the fabric is bonded between the dot-shaped welds. A first invention is an interior material having undulations on the surface, characterized in that a concave streak pattern formed by shrinking the fabric in a direction with a large heat shrinkage rate is formed.
Also, after setting the skin material with the fabric, cushion layer, and back base fabric laminated from the front side, mold the interior material by injecting the molten thermoplastic resin and integrally molding the skin material and the thermoplastic resin. The fabric has a difference in the vertical and horizontal heat shrinkage rates as the fabric, and the fabric and the back base fabric are welded in a dot shape at two points or more in the direction of the large heat shrinkage rate through the cushion layer. When the molten thermoplastic resin is poured into the mold, the fabric is shrunk in the direction where the thermal contraction rate of the fabric is large between the dotted welds due to the heat received from the molten resin. The second invention is a method for forming an interior material, characterized in that a dent streaks pattern is formed on the surface of the skin material.

本発明は、ファブリックとして縦横の熱収縮率に差を有しているとともに、ファブリックと裏基布とがクッション層を介して、熱収縮率の大きい方向に2点以上、ドット状に溶着されたものを用い、金型内に溶融した熱可塑性樹脂を注入した際に溶融樹脂からの受熱により、前記ドット状の溶着部間においてファブリックの熱収縮率の大きい方向に偏ってファブリックを縮ませて表皮材表面に凹み筋模様を形成するようにしたので、従来のように後加工することなく表皮材の表面に任意のデザインの起伏形状を一体的に成形することができることとなる。   In the present invention, the fabric has a difference in the vertical and horizontal heat shrinkage rates, and the fabric and the back base fabric were welded in a dot shape at two points or more in the direction of the large heat shrinkage rate through the cushion layer. When the molten thermoplastic resin is poured into the mold, the fabric is shrunk in the direction where the thermal contraction rate of the fabric is large between the dot-shaped welds due to the heat received from the molten resin. Since the concave streak pattern is formed on the surface of the material, an undulated shape of an arbitrary design can be integrally formed on the surface of the skin material without post-processing as in the prior art.

以下に、図面を参照しつつ本発明の好ましい形態を示す。
図面は、本発明を自動車用ドアトリムに適用した場合を示すものであり、図1は一部切欠した斜視図、図2は表皮材の斜視図、図3は表皮材の収縮率が小さい方向の拡大断面図、図4は表皮材の収縮率が大きい方向の拡大断面図である。
Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings.
FIG. 1 shows a case where the present invention is applied to an automobile door trim. FIG. 1 is a partially cutaway perspective view, FIG. 2 is a perspective view of a skin material, and FIG. 3 is a direction in which the shrinkage rate of the skin material is small. FIG. 4 is an enlarged cross-sectional view, and FIG. 4 is an enlarged cross-sectional view in a direction in which the shrinkage rate of the skin material is large.

図において、1は表面側からファブリック1a、ウレタン等の発泡材からなるクッション層1b、不織布等からなる裏基布1cを積層した表皮材、3は該表皮材1と一体的に成形された熱可塑性樹脂からなる樹脂層である。また、本発明では表皮材1は、ファブリック1aが縦横の熱収縮率に差を有しているとともに、ファブリック1aと裏基布1cとがクッション層1bを介して、熱収縮率の大きい方向に2点以上、ドット状に溶着されたものとなっている。   In the figure, 1 is a skin material in which a fabric 1a, a cushion layer 1b made of a foamed material such as urethane, and a back base fabric 1c made of a nonwoven fabric are laminated from the surface side, and 3 is a heat formed integrally with the skin material 1. It is a resin layer made of a plastic resin. In the present invention, the skin material 1 has a fabric 1a that has a difference in the vertical and horizontal thermal contraction rates, and the fabric 1a and the back base fabric 1c are arranged in a direction in which the thermal contraction rate is large via the cushion layer 1b. Two or more points are welded in a dot shape.

ここで、ファブリック1aが縦横の熱収縮率に差を有しているものとするのは、後述するように、溶融樹脂からの受熱によりファブリック1aの縦横の熱収縮に差異を生じさせ、この現象を利用して任意の方向のみに凹み筋模様4を形成するためである。
なお、ファブリック1aの熱収縮が生じるのは、原反製作時において生地の幅を調整する目的でファイナルセットと称される引張力をかけた状況(歪を発生させた状況)下での加熱処理(約100〜200℃)が施されており、内装材の成形工程において溶融樹脂からの受熱がファイナルセットの温度以上となった場合に、ファブリック1aが熱収縮するからである。従って、ファブリック1aの縦横の熱収縮率(歪量の差)に大きな差があればあるほど鮮明な凹み筋模様4を形成できることとなる。
具体的には、例えば編物であれば縦糸と横糸の熱収縮率が異なったものでファブリック生地を成形し、また織物であれば縦横の熱収縮率が異なるようにファイナルセット処理を行えばよい。
Here, the reason why the fabric 1a has a difference in the vertical and horizontal heat shrinkage ratio is that, as will be described later, a difference is caused in the vertical and horizontal heat shrinkage of the fabric 1a by receiving heat from the molten resin. This is because the dent streak pattern 4 is formed only in an arbitrary direction by using.
The heat shrinkage of the fabric 1a is caused by heat treatment under a situation where a tensile force called a final set is applied (a situation in which distortion is generated) for the purpose of adjusting the width of the fabric during the production of the original fabric. This is because the fabric 1a is thermally contracted when the heat received from the molten resin becomes equal to or higher than the final set temperature in the molding process of the interior material. Therefore, the greater the difference between the vertical and horizontal thermal contraction rates (difference in strain) of the fabric 1a, the clearer the dent streaks pattern 4 can be formed.
Specifically, for example, in the case of a knitted fabric, a fabric fabric may be formed with warp and weft having different heat shrinkage rates.

また、ファブリック1aと裏基布1cとがクッション層1bを介して、熱収縮率の大きい方向に2点以上、ドット状に溶着されたものとすることで、隣接する溶着部2,2間においてファブリック1aを熱収縮率させ、より鮮明な凹み筋模様4を形成することができる。
なお、図示のものでは、ドット状の溶着部2を格子状に規則正しく形成したものとしてあるが、波状やジグザグ状や渦巻状等、任意の模様に形成することが可能である。
In addition, the fabric 1a and the back base fabric 1c are welded in the form of dots at two points or more in the direction with a large heat shrinkage rate via the cushion layer 1b, so that between the adjacent welded portions 2 and 2 The fabric 1a can be heat-shrinkable to form a clearer dent line pattern 4.
In the illustrated example, the dot-shaped welds 2 are regularly formed in a lattice shape, but can be formed in an arbitrary pattern such as a wave shape, a zigzag shape, or a spiral shape.

次に、本発明の内装材の成形方法について説明すると、表面側からファブリック1a、クッション層1b、裏基布1cを積層した表皮材1を金型内にセットした後、溶融した熱可塑性樹脂を注入する、いわゆる射出成形あるいは熱可塑性樹脂を金型内に注入した後、金型を閉じて樹脂を押し広げるスタンピングモールド成形により表皮材1と熱可塑性樹脂を一体成形する点は従来の内装材の成形方法と基本的に同じである。
本発明では、前記ファブリック1aとして縦横の熱収縮率に差を有しているとともに、ファブリック1aと裏基布1cとがクッション層1bを介して、熱収縮率の大きい方向に2点以上、ドット状に溶着されたものを用いる。そして、これにより金型内に溶融した熱可塑性樹脂を注入した際に、溶融樹脂からの受熱によって、前記ドット状の溶着部2,2間においてファブリック1aの熱収縮率の大きい方向に偏ってファブリック1aを縮ませて表皮材表面に凹み筋模様4を形成する点に特徴を有する。
Next, the molding method of the interior material of the present invention will be described. After setting the skin material 1 in which the fabric 1a, the cushion layer 1b, and the back base fabric 1c are laminated from the front side in the mold, the molten thermoplastic resin is used. The point of integrally molding the skin material 1 and the thermoplastic resin by stamping mold molding that injects so-called injection molding or thermoplastic resin into the mold and then closes the mold and pushes the resin is that of the conventional interior material This is basically the same as the molding method.
In the present invention, the fabric 1a has a difference in the vertical and horizontal heat shrinkage rates, and the fabric 1a and the back base fabric 1c have two or more dots in the direction in which the heat shrinkage rate is large via the cushion layer 1b. What was welded in the shape is used. Thus, when the molten thermoplastic resin is injected into the mold, the fabric is biased in the direction in which the thermal contraction rate of the fabric 1a is large between the dot-shaped welded portions 2 and 2 due to heat received from the molten resin. It is characterized in that 1a is contracted to form a concave streak pattern 4 on the surface of the skin material.

即ち、図3に示されるように、ファブリック1aの熱収縮率の小さい方向においては、金型内に溶融した熱可塑性樹脂を注入した際に受熱がファイナルセットの温度以上となっても、歪が小さいため熱収縮は小さく、ほぼそのままの形状を維持することとなる。
一方、図4に示されるように、ファブリック1aの熱収縮率の大きい方向においては、金型内に溶融した熱可塑性樹脂を注入した際に受熱がファイナルセットの温度以上となると、歪が大きいため熱収縮が大きくなる。この時、ファブリック1aと裏基布1cとはクッション層1bを介して、熱収縮率の大きい方向に2点以上、ドット状に溶着されているので、隣接する溶着部2,2間において該溶着部2を区切りにファブリック1aが縮んで表皮材表面に深さdの鮮明な凹み筋模様4を形成することとなる。なお、溶着部2のない部分は区切りがなく全体的に縮むため、極所的な凹みは形成されず凹み筋模様とはならない。
この結果、ファブリック1aの熱収縮率の大きい方向に偏って、隣接する溶着部2を区切りとした鮮明な凹み筋模様4が形成されることとなる。
That is, as shown in FIG. 3, in the direction in which the thermal contraction rate of the fabric 1a is small, even when the molten thermoplastic resin is injected into the mold and the heat receiving temperature is equal to or higher than the final set temperature, the distortion does not occur. Since it is small, the heat shrinkage is small and the shape is maintained as it is.
On the other hand, as shown in FIG. 4, in the direction in which the thermal contraction rate of the fabric 1a is large, when the molten thermoplastic resin is injected into the mold and the heat receiving temperature is equal to or higher than the final set temperature, the strain is large. Thermal contraction increases. At this time, since the fabric 1a and the back base fabric 1c are welded in the form of dots at two points or more in the direction in which the thermal contraction rate is large via the cushion layer 1b, the welding is performed between the adjacent welded portions 2 and 2. The fabric 1a shrinks with the section 2 as a partition, and a clear dimple pattern 4 having a depth d is formed on the surface of the skin material. In addition, since the part which does not have the welding part 2 does not have a division | segmentation and shrinks as a whole, a local dent is not formed and it does not become a dent streak pattern.
As a result, a clear dent streak pattern 4 with the adjacent welded portions 2 as a partition is formed in the direction in which the thermal contraction rate of the fabric 1a is large.

以上の説明からも明らかなように、本発明はファブリック1aとして縦横の熱収縮率に差を有しているとともに、ファブリック1aと裏基布1cとがクッション層1bを介して、熱収縮率の大きい方向に2点以上、ドット状に溶着されたものを用い、金型内に溶融した熱可塑性樹脂を注入した際に溶融樹脂からの受熱により、前記ドット状の溶着部2,2間においてファブリック1aの熱収縮率の大きい方向に偏ってファブリック1aを縮ませて表皮材表面に凹み筋模様4を形成するようにしたので、従来のように後加工することなく通常の成形工程中において起伏形状を一体的に成形することができるものである。また、ドット状の溶着部2のパターンを変えたり、金型内にセットする表皮材1の方向を変える等することにより任意の凹み筋模様4を形成することができ、内装材としてデザインの幅を広げることが可能である。   As is clear from the above description, the present invention has a difference in the vertical and horizontal thermal contraction rates as the fabric 1a, and the fabric 1a and the back base fabric 1c have a thermal contraction rate via the cushion layer 1b. When two or more dots are welded in a large direction in the form of dots and a molten thermoplastic resin is injected into the mold, the fabric is formed between the dot-shaped welds 2 and 2 by receiving heat from the molten resin. Since the fabric 1a is shrunk in the direction in which the thermal contraction rate of 1a is large and the dent streaks pattern 4 is formed on the surface of the skin material, the undulating shape is formed during the normal molding process without post-processing as in the prior art Can be formed integrally. Further, by changing the pattern of the dot-like welded portion 2 or changing the direction of the skin material 1 set in the mold, an arbitrary dent streaked pattern 4 can be formed, and the width of the design as an interior material Can be expanded.

本発明の実施の形態を示す斜視図である。It is a perspective view which shows embodiment of this invention. 表皮材を示す斜視図である。It is a perspective view which shows a skin material. 表皮材の収縮率が小さい方向の拡大断面図である。It is an expanded sectional view of the direction where the shrinkage rate of a skin material is small. 表皮材の収縮率が大きい方向の拡大断面図である。It is an expanded sectional view in the direction where the shrinkage rate of the skin material is large.

符号の説明Explanation of symbols

1 表皮材
1a ファブリック
1b クッション層
1c 裏基布
2 ドット状溶着部
3 樹脂層
4 凹み筋模様
DESCRIPTION OF SYMBOLS 1 Skin material 1a Fabric 1b Cushion layer 1c Back base fabric 2 Dot-shaped weld part 3 Resin layer 4 Recessed streaks pattern

Claims (3)

表面側からファブリック、クッション層、裏基布を積層した表皮材を金型内にセット後、溶融した熱可塑性樹脂を注入して表皮材と熱可塑性樹脂とを一体成形した内装材であって、前記ファブリックが縦横の熱収縮率に差を有しているとともに、ファブリックと裏基布とがクッション層を介して、熱収縮率の大きい方向に2点以上、ドット状に溶着されたものであり、表皮材表面には金型内に溶融した熱可塑性樹脂を注入した際の溶融樹脂からの受熱により、前記ドット状の溶着部間においてファブリックの熱収縮率の大きい方向に偏ってファブリックが縮んで生じた凹み筋模様が形成されていることを特徴とする表面に起伏を有する内装材。   An interior material in which a skin material in which a fabric, a cushion layer, and a back base fabric are laminated from the front surface side is set in a mold, and then a molten thermoplastic resin is injected to integrally mold the skin material and the thermoplastic resin, The fabric has a difference in the vertical and horizontal heat shrinkage rates, and the fabric and the back base fabric are welded in a dot shape at two points or more in the direction of the large heat shrinkage rate through the cushion layer. The surface of the skin material shrinks in a direction in which the thermal contraction rate of the fabric is large between the dot-shaped welds due to heat received from the molten resin when the molten thermoplastic resin is injected into the mold. An interior material having undulations on the surface, wherein the resulting dent streaks are formed. 表面側からファブリック、クッション層、裏基布を積層した表皮材を金型内にセットした後、溶融した熱可塑性樹脂を注入して表皮材と熱可塑性樹脂を一体成形した内装材の成形方法であって、前記ファブリックとして縦横の熱収縮率に差を有しているとともに、ファブリックと裏基布とがクッション層を介して、熱収縮率の大きい方向に2点以上、ドット状に溶着されたものを用い、金型内に溶融した熱可塑性樹脂を注入した際に溶融樹脂からの受熱により、前記ドット状の溶着部間においてファブリックの熱収縮率の大きい方向に偏ってファブリックを縮ませて表皮材表面に凹み筋模様を形成することを特徴とする内装材の成形方法。   After setting the skin material with the fabric, cushion layer, and back base fabric laminated from the front side in the mold, the molten thermoplastic resin is injected and the skin material and the thermoplastic resin are integrally molded. In addition, the fabric has a difference in heat shrinkage between the length and breadth, and the fabric and the back base fabric were welded in a dot shape at two points or more in the direction in which the heat shrinkage is large through the cushion layer. When the molten thermoplastic resin is poured into the mold, the fabric is shrunk in the direction where the thermal contraction rate of the fabric is large between the dot-shaped welds due to the heat received from the molten resin. A method for forming an interior material, comprising forming a dent streak pattern on a material surface. 溶融樹脂からの受熱をファブリックのファイナルセット時の温度以上とする請求項2に記載の成形方法。
The molding method according to claim 2, wherein heat received from the molten resin is equal to or higher than a temperature at the time of final setting of the fabric.
JP2004320261A 2004-11-04 2004-11-04 Trim material having undulated surface and its molding method Withdrawn JP2006130715A (en)

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Cited By (3)

* Cited by examiner, † Cited by third party
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JP2014111403A (en) * 2012-12-05 2014-06-19 Inoac Corp Method of manufacturing vehicular interior member
WO2015114874A1 (en) 2014-01-31 2015-08-06 株式会社タチエス Vehicle seat and method of manufacturing vehicle seat
JP7463234B2 (en) 2020-09-01 2024-04-08 株式会社Howa Vehicle interior cover

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2014111403A (en) * 2012-12-05 2014-06-19 Inoac Corp Method of manufacturing vehicular interior member
WO2015114874A1 (en) 2014-01-31 2015-08-06 株式会社タチエス Vehicle seat and method of manufacturing vehicle seat
CN105939891A (en) * 2014-01-31 2016-09-14 株式会社塔捷斯 Vehicle seat and method of manufacturing vehicle seat
KR20160124090A (en) 2014-01-31 2016-10-26 가부시끼가이샤 타치에스 Vehicle seat and method of manufacturing vehicle seat
US10414305B2 (en) 2014-01-31 2019-09-17 Tachi-S Co., Ltd. Vehicle seat and method of manufacturing vehicle seat
JP7463234B2 (en) 2020-09-01 2024-04-08 株式会社Howa Vehicle interior cover

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